Godrej & Boyce deployed over 80 RPA bots for automation, resulting in enhanced productivity and reduced errors

In an exclusive interview, Amit Chawla, the Head of Digital Projects at Godrej & Boyce, provides insightful perspectives on the strategic integration of deep tech solutions like robotics and automation into the company's manufacturing processes. By addressing pressing societal challenges such as climate change, rising energy costs, and the shortage of skilled workforce, Godrej & Boyce exemplifies its commitment to the triple bottom line - protecting people and the planet while creating value for shareholders. Chawla sheds light on how technology, particularly robotics, automation, AI, and IIoT, has revolutionized manufacturing operations, driving efficiency, sustainability, and resilience in the face of evolving industry demands. Through strategic investments in digital transformation, Godrej & Boyce continues to lead the charge towards a more sustainable and technologically advanced future in the manufacturing sector.

How has Godrej & Boyce strategically integrated deep tech solutions like robotics and automation into its manufacturing processes to address pressing societal challenges such as climate change, rising energy costs, and the shortage of skilled workforce? 

At Godrej & Boyce, we actively champion a strong social conscience towards all our stakeholders. Our Good and Green philosophy emanates from a strong belief in the value of the triple bottom line - protection of people and the planet while creating value for shareholders. We believe technology can be leveraged significantly to achieve our sustainability goals. For instance, we utilize articulated robots for repetitive tasks and collaborative robots for welding and assembly, leading to improved efficiency and reduced labor dependency. Additionally, the adoption of 3D printing enables us to achieve low-volume production and mass customization, aiding in faster product development. Furthermore, we have deployed over 80 RPA bots for automation, resulting in enhanced productivity and reduced errors. These initiatives have not only improved our operational efficiency but also contributed to various sustainability initiatives – for instance doubling our energy productivity over the last decade.

Can you provide specific examples of how robotics and automation have improved efficiency and sustainability within Godrej & Boyce's manufacturing operations?  

Additive Manufacturing (3D Printing): The integration of additive manufacturing or 3D printing into our processes has enabled low-volume production and mass customization of tooling and complex parts. This adoption has significantly improved our product design and time to market.

Intelligent Automation: We have deployed over 80 Robotic Process Automation (RPA) bots across our value chain to automate manual processes. This deployment has led to productivity improvements, error reduction, and enhanced employee experience within our organization.

Energy Productivity: We have doubled our energy productivity over the last decade by focusing on enhancing operational efficiency and deploying greener technologies using real-time data and analytics. This holistic energy management process has led to significant improvements in energy efficiency.

Sustainable Manufacturing Techniques: We employ sustainable manufacturing techniques to reduce environmental impact, increase productivity, and minimize waste. By leveraging modern technology, we have been able to improve productivity, reduce wastage, and lessen the burden on manual labor, thus contributing to sustainability in our manufacturing unit.

Industry 4.0 Technologies: The adoption of Industry 4.0 technologies like Artificial Intelligence (AI) and Machine Learning (ML) has had a profound impact on our productivity and sustainability. These technologies are used to analyze data from our manufacturing processes, improve supply chain management, enable predictive maintenance, enhance quality control, and optimize various operations within our manufacturing unit.

Digital Transformation: Through initiatives like conversational AI and Robotic Process Automation (RPA), we have enhanced end customer and employee experiences. By leveraging digital technologies effectively, we have streamlined processes, built new skill sets among employees, engaged with customers across social and online platforms, and overall improved operational efficiency.

In what ways has the implementation of AI and IIoT (Industrial Internet of Things) contributed to enhancing productivity, quality control, and predictive maintenance in your manufacturing facilities? 

Real-time Visibility and Data Acquisition: We have implemented an enterprise-wide IIoT platform that acquires data from machines, providing us with real-time visibility of our production facilities. This platform enables advanced analytics with edge AI and intelligent workflows, helping us enhance productivity, quality, on-time delivery, reduce production costs, and optimize energy utilization.

Product Quality Improvement: By applying advanced analytics, AI, and ML algorithms, we have improved product quality and reduced defects in our manufacturing processes. We utilized AI and ML to find the ideal parameters for the production process, resulting in a 40% decrease in defects and improved customer satisfaction. Additionally, an AI-based production optimization tool has enhanced our through put by 25% and minimized stockouts.

Predictive Maintenance: We have leveraged AI and IIoT technologies to enable predictive maintenance in our manufacturing facilities. By analyzing data from machines and implementing intelligent workflows, we can proactively address maintenance needs, reduce downtime, optimize machine availability, increase overall equipment efficiency (OEE), and lower the cost of production.

Could you provide insights into the strategic investments Godrej & Boyce has made in digital transformation? How do these investments support your role in leading and managing the execution of digital initiatives both at the group level and within specific business units? 

Enterprise-Wide IIoT Platform: We have implemented an enterprise-wide Industrial Internet of Things (IIoT) platform that acquires data from machines, providing us with real-time visibility of our production facility. This platform enables advanced analytics with edge AI and intelligent workflows, helping us enhance productivity, quality, on-time delivery, reduce production costs, and optimize energy utilization.

Integrated CRM Platform: We have invested in composable, modular, cloud-based platforms that can be deployed across our organization. These platforms enable multiple business units to have a 360-degree view of the customer and integrate efforts across sales, marketing, e-commerce, and service teams.

Conversation AI : Our chatbots leverage Conversation AI to help us to streamline and optimize the post purchase experience. Smart Care Whatsapp chatbot has been deployed for our B2C businesses – Interio, Appliances, Security Solutions and Locks to provide a 24x7 solution to customer queries and faster resolution rates.

IoT enabled Products and Services: We have developed connected products and services, such as smart appliances, digital locks, and security cameras. These products allow consumers to control them from their voice assistants or smartphones while enabling our customers and product service teams to monitor and maintain them remotely.

With the ongoing advancements in deep tech and digitalization, what are the key areas of focus for Godrej & Boyce in terms of further leveraging technology to drive sustainable growth and resilience in the manufacturing sector?

Digitalization for Sustainable Growth:

Technological Focus: At Godrej & Boyce, we prioritize leveraging digital technologies to drive sustainable growth in the manufacturing sector.

Key Technologies: We focus on Big Data Analytics, Artificial Intelligence (AI), Machine Learning (ML), and Robotics and Automation to collect, analyze, and implement data-driven strategies.

Operational Efficiency: Technology plays a pivotal role in improving operational efficiency, leading to resource conservation.

IoT for Remote Monitoring: Internet of Things (IoT) allows us to monitor and manage machinery and equipment remotely, reducing downtime and energy consumption.

Implementation of IIoT Platform:

Real-time Visibility: We have implemented an enterprise-wide IIoT platform that acquires data from machines, providing real-time visibility of the product and process to the shop floor personnel.

Advanced Analytics: The platform enables advanced analytics with edge AI and intelligent workflows to enhance productivity, quality, on-time delivery, and reduce production costs and energy utilization.

Advanced Logistics Platform:

Efficient Dispatch: Our advanced Logistics platform enables our dispatch teams to plan efficient loading of trucks and provides real-time visibility of the product delivery to the end-customer.

Data Utilization and Cloud Modernization:

Data-driven Decision Making: With a data platform and ongoing cloud modernization initiatives, we leverage data for advanced analytics use cases in manufacturing, supply chain, sales, marketing, and customer service teams.

Benefits: This approach makes our operations more agile, improves efficiency, and enhances overall customer experience.

Continued Investment in Digital Transformation:

Organizational Reshaping: We continue to invest in Digital Transformation to optimize our operations as per business goals, upskill our employees to be future-ready, and leverage emerging technologies